Aerospace Metallics Machining Methods Engineer

1 month ago

Hyderabad, Telangana, India skyroot Full time

About Skyroot Aerospace

A cutting-edge startup founded by ex-ISRO scientists, dedicated to affordable space access, rewriting aerospace technology rules. Our dynamic team fosters inventiveness, collaboration, and relentless excellence. Welcome to the forefront of space innovation with Skyroot Aerospace.


Purpose of Role：

An Aerospace Metallics Machining Methods Engineer specializes in the development, optimization, and management of machining processes for metallic components used in aerospace applications. This role involves ensuring that metallic parts (e.g., aluminum, titanium, steel, nickel alloys) are manufactured to high precision, meeting the stringent performance, quality, and safety requirements of the aerospace industry. The engineer works closely with design, manufacturing, and quality teams to ensure cost-effective and reliable production.

1. Process Design and Development

  • Develop and optimize machining processes for aerospace metallic components, focusing on materials such as aluminum, titanium, stainless steel, and superalloys (e.g., Inconel).
  • Collaborate with design engineers to review product designs for manufacturability, ensuring that components can be efficiently and accurately machined.
  • Create and simulate CNC machining programs (using CAD/CAM software such as CATIA, Siemens NX, ESPRIT, or Mastercam) to manufacture complex aerospace components.
  • Develop detailed process documentation, including machining sequences, tool selection, cutting parameters, and work instructions.

2. Tooling and Equipment Optimization

  • Select and design appropriate cutting tools, jigs, fixtures, and work-holding devices to optimize machining processes.
  • Work closely with tool suppliers to ensure the selection of tools that maximize efficiency, tool life, and precision.
  • Evaluate the performance of CNC machines (e.g., lathes, mills, multi-axis machines) and optimize machine settings to achieve the best balance of speed, accuracy, and tool life.
  • Investigate and recommend new machining technologies (e.g., high-speed machining, adaptive machining, and robotic systems) to improve productivity and quality.

3. Process Optimization and Continuous Improvement

  • Analyze existing machining processes to identify inefficiencies, bottlenecks, and opportunities for improvement.
  • Implement lean manufacturing principles, such as Six Sigma and Kaizen, to reduce waste, improve cycle times, and increase overall process efficiency.
  • Conduct root cause analysis on machining defects, such as surface finish issues, dimensional inaccuracies, or tool wear, and implement corrective actions.
  • Continuously monitor and adjust machining parameters to ensure that the production process remains cost-effective, reliable, and capable of meeting tight aerospace tolerances.

4. Quality Control and Assurance

  • Collaborate with quality assurance teams to ensure that all machined parts meet aerospace industry standards (e.g., AS9100) and customer specifications.
  • Develop inspection protocols and in-process checks, including first-article inspection (FAI) and statistical process control (SPC), to monitor machining accuracy.
  • Ensure that all machining processes comply with aerospace quality standards and regulatory requirements.
  • Address nonconformities by conducting failure analysis and implementing process improvements.

5. Material and Machining Expertise

  • Develop expertise in the machining of aerospace-grade metallic materials, such as aluminum alloys, titanium alloys, stainless steels, and superalloys.
  • Optimize cutting speeds, feed rates, and cooling/lubrication methods for each material to ensure optimal surface finishes, dimensional accuracy, and tool life.
  • Troubleshoot challenges associated with difficult-to-machine materials, such as titanium and nickel-based alloys, ensuring minimal tool wear and high-quality finishes.

6. Project Management and Collaboration

  • Lead machining process development projects from initial concept to full-scale production, ensuring that projects are completed on time and within budget.
  • Work closely with cross-functional teams, including design, manufacturing, quality, and procurement, to ensure alignment on project goals.
  • Prepare and present technical reports and process updates to internal and external stakeholders, including customers and management.
  • Coordinate with suppliers and vendors for equipment procurement, tooling design, and material selection.

7. Compliance and Safety

  • Ensure that all machining processes comply with aerospace industry standards, including AS9100 and NADCAP.
  • Develop and implement safety protocols and guidelines for machining processes, including the handling of hazardous materials (e.g., coolant, metal dust).
  • Ensure compliance with environmental regulations related to waste management, coolant disposal, and energy consumption.
  • Promote a safe working environment by conducting risk assessments and implementing safety measures for CNC machine operators and staff.

8. Research and Development

  • Stay updated on the latest advancements in machining technologies and materials relevant to aerospace manufacturing.
  • Explore and implement innovative machining techniques, such as 5-axis machining, automated inspection systems, and digital twin technology.
  • Research new materials and machining strategies to support the development of next-generation aerospace components that are lighter, stronger, and more fuel-efficient.
Skills:
  • Machining Expertise: Strong knowledge of CNC programming, milling, turning, grinding, and drilling processes, particularly for aerospace applications.
  • Material Knowledge: In-depth understanding of machining aerospace-grade metals (aluminum, titanium, Inconel, stainless steel).
  • CAD/CAM Proficiency: Skilled in CAD/CAM software for designing and programming machining processes (e.g., CATIA, Siemens NX, Mastercam, ESPRIT).
  • Quality Control: Knowledge of aerospace quality standards (AS9100, NADCAP) and experience with SPC, FAI, and other quality assurance tools.
  • Problem-Solving: Strong analytical and troubleshooting skills for addressing machining issues and optimizing processes.
  • Project Management: Ability to lead and manage complex machining projects, coordinating with cross-functional teams and external suppliers.

Educational Qualifications:

Bachelor's/ Master's degree in mechanical engineering, Aerospace Engineering, Manufacturing Engineering, or a related field.

Certifications (Optional but beneficial):

  • CNC Programming Certification
  • Six Sigma Green/Black Belt certification for process optimization
  • Lean Manufacturing certifications or equivalent

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